Infusion tube system and method for manufacture

ABSTRACT

An infusion tube system and a method for manufacture are provided. An infusion tube system including an infusion tube and a connector attached to the infusion tube at an end of the infusion tube is disclosed. The connector has a proximal end and includes a connector body extending from a distal end to a proximal end along a center axis and defining a cavity. The connector body includes an end wall with an inner surface, and at least one vent opening, and a sidewall extending from the end wall along the center axis with an inner and outer surface. The connector includes a membrane covering the at least one vent opening, the membrane being welded to the inner surface of the end wall along at least one welding seam including a first welding seam such that the membrane covers and seals the at least one vent opening.

RELATED APPLICATIONS

This application is a continuation application of, and claims the priority benefit of, U.S. application Ser. No. 17/398,535, which was filed on Aug. 10, 2021, and which is a continuation application of U.S. application Ser. No. 15/282,825 entitled “INFUSION TUBE SYSTEM AND METHOD FOR MANUFACTURE,” which was filed on Sep. 30, 2016, and which is a continuation of U.S. application Ser. No. 13/652,722, which was filed on Oct. 16, 2012, and which claims the priority benefit of U.S. Provisional Application Ser. No. 61/548,871 and European Application No. 11185747.0, each of which was filed on Oct. 19, 2011. Those applications are incorporated by reference herein in their entireties.

TECHNICAL FIELD

The present invention relates to an infusion tube system and a method for manufacture of an infusion tube system, in particular an infusion tube system for coupling to an infusion port of an infusion device.

BACKGROUND

Present tube systems, in particular tube systems for infusion, comprise a tube and a connector attached to an end of the tube in order to couple the tube to other devices, such as an infusion device or an inserter device.

Cost-effective manufacture of infusion tube systems for infusion devices requires low or reduced material costs and low or no scrap rate in the production process. Further, it may be desirable to reduce or remove one or more processes in the manufacture cycle.

SUMMARY

Thus there is a need for devices and methods for reducing material waste in production or manufacture of infusion tube systems. Further, there may be a need for infusion tube systems enabling use of simple infusion devices, e.g. infusion devices with simple coupling systems.

Accordingly, an infusion tube system is provided, the infusion tube system comprising an infusion tube and a connector attached to the infusion tube at an end of the infusion tube, the connector having a proximal end and comprising a connector body extending from a distal end to a proximal end along a center axis and defining a cavity, the connector body comprising an end wall with an inner surface, and at least one vent opening including a first vent opening, and a sidewall extending from the end wall along the center axis with an inner and outer surface. The connector comprises a membrane covering the at least one vent opening, the membrane being welded to the inner surface of the end wall along at least one welding seam including a first welding seam such that the membrane covers and seals the at least one vent opening.

It is an important advantage of the present invention that membrane material covering the vent openings has not been subject to substantial heat caused by the welding process, thereby ensuring that the membrane material function as intended leading to more effective manufacture of infusion tube systems due to reduced material waste. Further, the present invention enables a more effective manufacture of tube infusion system due to smaller number of defective tube infusions system and a reduced scrap rate.

Further disclosed is a method for manufacture of an infusion tube system comprising an infusion tube and a connector, the method comprising providing a connector with a connector body extending from a distal end to a proximal end along a center axis and defining a cavity, the connector body comprising an end wall with an inner surface, and at least one vent opening including a first vent opening, and a sidewall extending from the end wall along the center axis with an inner and outer surface. The method further comprises providing a membrane at the inner surface of the end wall, and welding the membrane to the inner surface of the end wall along at least one welding seam including a first welding seam such that the membrane covers and seals the at least one vent opening.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and advantages of the present invention will become readily apparent to those skilled in the art by the following detailed description of exemplary embodiments thereof with reference to the attached drawings, in which:

FIG. 1 is a first perspective view of an exemplary infusion tube system;

FIG. 2 is a second perspective view of the infusion tube system in FIG. 1 ;

FIG. 3 is an end view of the infusion tube system in FIG. 1 seen from the distal end of the connector perpendicular to the center axis;

FIG. 4 is a cross section U-U of the infusion tube system in FIG. 1 as indicated in FIG. 5 ;

FIG. 5 shows an infusion tube system perpendicular to the center axis;

FIG. 6 is a detailed view of a part of the infusion tube system as indicated by the circle in FIG. 4 ;

FIG. 7 is a side view of infusion tube systems;

FIG. 8 is a cross section A-A of infusion tube systems as indicated in FIG. 7 ;

FIG. 9 is a first perspective view of an exemplary infusion tube system;

FIG. 10 is a second perspective view of the infusion tube system in FIG. 9 ;

FIG. 11 is an end view of the infusion tube system in FIG. 9 seen from the distal end of the connector perpendicular to the center axis;

FIG. 12 is a side view of the infusion tube system of FIG. 9 ;

FIG. 13 is a cross section O-O of the infusion tube system of FIG. 9 as indicated in FIG. 12 ;

FIG. 14 is a detailed view of a part of the infusion tube system as indicated by the circle in FIG. 13 ;

FIG. 15 is a perspective view of an exemplary weld horn used for manufacture of the infusion tube system of FIG. 1-6 ;

FIG. 16 schematically illustrates steps of the method according to the present invention; and

FIG. 17 is a cross section U-U of an exemplary infusion tube system as indicated in FIG. 5 .

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The figures are schematic and simplified for clarity, and they merely show details which are essential to the understanding of the invention, while other details have been left out. Throughout, the same reference numerals are used for identical or corresponding parts.

The infusion tube system comprises an infusion tube and a connector at an end, e.g. a first end, of the infusion tube. The connector may be adapted for coupling to an inlet or outlet port of an infusion device having a housing accommodating a pump device and a reservoir with medicine, e.g. insulin, or other infusion liquid.

The connector has a distal end, a proximal end and a connector body extending from a distal end to a proximal end of the connector body along a center axis and defining a cavity.

The connector body comprises an end wall with an inner surface, and at least one sidewall extending from the end wall along the center axis and having an inner and outer surface. The inner surface of the end wall and the sidewall define or at least partly define the cavity. The cavity may be cylindrical or at least partly cylindrical with a cross section of suitable size and shape, i.e. the inner surface of the sidewall may have a cross section perpendicular to the center axis, the cross section being substantially constant along at least a part of the center axis. In one or more embodiments, cross section areas of the cavity may increase towards the distal end of the connector. The cavity may be cylindrical with a circular or non-circular (oval, polygonal or elliptical) inner surface cross-section perpendicular to the center axis.

The end wall comprises at least one vent opening including a first vent opening. The at least one vent opening connects or communicates the cavity with the surroundings through the end wall and a membrane covering the at least one vent opening. The at least one vent opening may include a plurality of vent openings including the first vent opening and a second vent opening formed in the end wall. Further, a third and/or fourth vent opening may be formed in the end wall. A vent opening may have any suitable size and shape. In one or more embodiments, one or more vent openings are circular, elliptical, kidney-shaped or oval, e.g. with a diameter or maximum extension less than 8 mm, such as in the range from 0.5 mm to 5 mm. In one or more embodiments, one or more vent openings may have an area in the range from 0.3 mm² to 20 mm². The area of the respective vent openings depends e.g. on the number of vent openings in the end wall and the available inner surface area of the end wall. In one or more embodiments with three to six vent openings, the area of each vent opening may be in the range from 0.3 mm² to 2 mm². In one or more embodiments, with one or two vent openings, the area of the vent openings may be in the range from 1.0 mm² to 10 mm².

The connector comprises a membrane covering the at least one vent opening including the first vent opening and other vent openings if present. The membrane is welded to an inner surface defining the cavity. The membrane may be welded to the inner surface of the end wall such that the membrane covers and seals the at least one vent opening including the first vent opening and other vent openings if present. Thus air or other gasses must pass the membrane in order to flow from the cavity to the surroundings through the at least one vent opening, e.g. in order to equalize pressure between the cavity and the surroundings. The membrane enables pressure equalization of a cavity within an infusion device through the vent opening and at the same time providing a substantially liquid tight infusion device when the infusion tube system is connected to the infusion port of the infusion device.

The membrane is welded to the inner surface of the end wall along at least one welding seam including a first welding seam and optionally a second welding seam. The first welding seam and/or the second welding seam may form a dosed curve. The first welding seam may surround at least the first vent opening. In one or more embodiments, the first welding seam surrounds all the vent openings in the end wall. In one or more embodiments, the second welding seam may if present form a closed curve surrounding a fluid path opening or a connector needle in the end wall.

The second welding seam may form a dosed curve surrounding one or more vent openings including a second vent opening in the end wall.

The first welding seam may form a dosed outer welding seam and the second welding seam may form a dosed inner welding seam surrounded by the outer welding seam, wherein the membrane area between the inner welding seam and the outer welding seam covers at least one vent opening, e.g. the first vent opening. In one or more embodiments, the membrane area between an inner welding seam and an outer welding seam covers all vent openings in the end wall. Welding seams may cross each other.

In one or more embodiments welding seam(s), e.g. the first welding seam and/or a second welding seam, forms a dosed curve surrounding one or more vent openings and wherein the connector needle or a fluid path opening in the end wall is arranged outside the dosed curve of the welding seam.

A welding seam may have a suitable length which at least for an outer welding seam may depend on the number and configuration of vent openings to be surrounded. In one or more embodiments, the first welding seam may have a length in the range from 4 mm to about 100 mm, such as in the range from 10 mm to 50 mm, such as about 30 mm. The welding seam must be sufficiently wide to ensure sealing of the membrane to the inner surface of the cavity. On the other hand, the width of a welding seam is limited, e.g. in order to maximize the non-welded area of the membrane. Accordingly, a welding seam, e.g. the first welding seam and/or the second welding seam may have a width in the range from 0.1 mm to 3.0 mm, such as from 0.3 mm to 2.0 mm. In one or more embodiments, a welding seam width of 0.5 mm to 1 mm may be advantageous.

The total welding area being the sum of welding areas for respective welding seams may be less than 95% of the common area between the membrane and the inner surface of the end wall. In one or more embodiments, the total welding area is less than 90% of the common, i.e. overlapping, area between the membrane and the inner surface of the end wall.

The total welding area being the sum of welding areas for respective welding seams may be less than 90% of the area of the inner surface of the end wall. In one or more embodiments, the total welding area being the sum of welding areas for respective welding seams may be less than 70%, such as less than 50% of the area of the inner surface of the end wall.

The membrane is made of a suitable material in order to allow air or other gasses to flow through the membrane while substantially preventing liquid, e.g. water from the surroundings, to pass the membrane. The membrane may be air-permeable and may be made of or comprise a thermoplastic polymer, such as Polytetrafluoroethylene (PTFE). The membrane may be a hydrophobic membrane.

The membrane may be attached to the inner surface of the cavity by various welding methods, preferably by ultrasonic welding.

The connector may comprise a hollow connector needle with a distal end attached to the connector body and extending from the inner surface of the end wall into the cavity forming a fluid path between the infusion tube and the cavity. A fluid path opening may be formed in the inner surface of the end wall forming a fluid path between the infusion tube and the cavity.

The connector may comprise at least one annular protrusion including a first annular protrusion on the inner surface of the end wall, the first annular protrusion surrounding at least the first opening, wherein the membrane is welded to the inner surface of the end wall along the first annular protrusion.

The connector may comprise a support structure extending from the end wall in a proximal direction along the center axis. The support structure may define a support cavity accommodating at least a part of the infusion tube. Typically, a part of the outer surface of the infusion tube is attached to an inner surface of the support structure defining the support cavity.

FIG. 1-6 show different views of an infusion tube system according to the present invention. The infusion tube system 1 comprises an infusion tube 2 and a connector 4 attached to the infusion tube 2 at an end of the infusion tube 2. The connector 4 has a proximal end 6 and comprises a connector body 8 extending from a distal end 10 to a proximal end 12 along a center axis X and defining a cavity 14. The connector body 8 comprises an end wall 16 with an inner surface 18 and an outer surface 20. At least one vent opening including a first vent opening 22 is formed in the end wall 16. The connector 4 illustrated in FIGS. 1 and 2 has a second vent opening 24, and optionally a third vent opening 26 and/or a fourth vent opening 28 in the end wall 16. The connector body 8 comprises a sidewall 30 extending from the end wall 16 along the center axis X with an inner surface 32 and an outer surface 34. Further, the connector 4 comprises a membrane 36 covering the vent openings 22, 24, 26, 28. The membrane 36 is welded to the inner surface 18 of the end wall 16 along a first welding seam 38 and a second welding seam 40 such that the membrane 36 covers and seals the four vent openings 22, 24, 26, 28. The vent openings 22, 24, 26, 28 have a circular cross-section perpendicular to the center axis X with a diameter D₁, D₂, D₃, D₄, respectfully, of about 1 mm. The cavity 14 defined by the inner surfaces 18, 32 is cylindrical with a circular cross-section having a diameter of about 12 mm and a length of about 10 mm. The connector 4 optionally comprises a hollow connector needle 42 attached to the connector body 8 and extending from the inner surface 18 of the end wall 16 into the cavity 14. The connector needle 42 forms a fluid path from the flow channel in the infusion tube 2 to the distal end 44 of the hollow connector needle 42. In the absence of a connector needle, a fluid path opening in the end wall 16 may connect the flow channel of the infusion tube with the cavity 14.

The first welding seam 38 forms a closed curve in the form of a circle having a diameter in the range from 8 to 10 mm surrounding the first, second, third and fourth vent opening, and the second welding seam 40 forming a closed curve, e.g. a circle with a diameter e.g. of about 3.5 mm to 4.5 mm, surrounding the connector needle 42 and positioned on the inside of the vent openings as seen e.g. in the end view in FIG. 3 and in the detailed view in FIG. 6 . The first welding seam 38 forms a closed outer welding seam and the second welding seam 40 forms a closed inner welding seam surrounded by the outer welding seam 38, wherein the membrane area 46 between the inner welding seam and the outer welding seam covers the vent openings in the end wall, i.e. the four vent openings 22, 24, 26, 28 in this configuration. The first and second welding seams each have a width about 1 mm.

The membrane 36 is circular with a diameter about the diameter of the inner surface of the end wall (e.g. ±15%). An opening may be formed in the membrane to allow the connector needle to pass therethrough.

The connector 4 comprises a support structure 48 extending from the end wall 16 in a proximal direction along the center axis. The support structure 48 defines a cavity accommodating at least a part of the infusion tube, the infusion tube being attached to the inner surface defining the cavity, e.g. by gluing. The outer surface of the support structure 48 is adapted for facilitating manual handling of the infusion tube system, e.g. when the connector is to be connected to a device, such as an infusion port of an infusion device.

FIGS. 7 and 8 is a sideview of infusion tube systems 1, 100 and a cross-section A-A as indicated. The infusion tube systems 1, 100 are shown without membrane 36. A sealing element 50 is formed as an annular protrusion on the outer surface 34 and perpendicular to the center axis X. The sealing element 50 may be formed as an integrated part of and in the same material as the connector body 8. In one or more embodiments, the sealing element may be molded to the connector body in a two-step molding process, e.g. in a resilient material to facilitate coupling and sealing of the connector 4 at an infusion port. In one or more embodiments, the sealing element may be an a-ring at least partly accommodated in an annular recess at the outer surface 34 of the sidewall 30.

FIGS. 9-14 show different views of an infusion tube system according to the present invention. The infusion tube system 100 only has a first vent opening 22 in the end wall 16. A first welding seam 38 forms a closed oval curve surrounding the first vent opening 22, thereby sealing the first vent opening with the membrane 36. The connector needle 42 is arranged outside the closed curve of the first welding seam 38.

The first vent opening 22 in the infusion tube system 100 is oval and having an area of about 1.5 mm² (W=1 mm and length L=2 mm) A single or limited number of vent openings may allow for a smaller membrane leading to material cost savings. The membrane 36 of infusion tube system 100 is about half the size of the membrane area in infusion tube system 1 as shown in FIG. 1-6 .

FIG. 15 shows a weld horn used for manufacture of the infusion tube system 1. The weld horn 300 comprises a body 301 with a first annular protrusion 302 and second annular protrusion 304 for forming the first welding seam 38 and the second welding seam 40, respectively of infusion tube system 1.

FIG. 16 is a flow chart illustrating a method according to the invention namely a method for manufacture of an infusion tube system comprising an infusion tube and a connector. The method 400 comprises providing 402 a connector with a connector body extending from a distal end to a proximal end along a center axis and defining a cavity, the connector body comprising an end wall with an inner surface, and at least one vent opening including a first vent opening, and a sidewall extending from the end wall along the center axis with an inner and outer surface. Further, the method comprises providing 404 a membrane 36 at the inner surface of the end wall, and welding 406 by ultrasonic welding a membrane to the inner surface of the end wall along at least one welding seam including a first welding seam 38 such that the membrane covers and seals the at least one vent opening. Welding 406 comprises pressing the membrane between the connector body 8 and a weld horn 300 comprising at least one annular weld protrusion forming at least one welding seam.

FIG. 17 shows a cross-section of an exemplary infusion tube system 102. For illustrative purposes, the membrane is not shown in FIG. 17 . The connector 4 comprises at least one protrusion extending from the inner surface 18 of the end wall in the distal direction, i.e. towards the distal end 10. The at least one protrusion comprises a first protrusion 52 forming a circular or annular protrusion, e.g. surrounding the vent openings 22, 24, 26, 28. Further, a second protrusion 54 forms a circular or annular protrusion by the first protrusion, wherein the vent openings 22, 24, 26, 28 are positioned between the first protrusion 52 and the second protrusion 54 radially from the center axis. The protrusions 52, 54 may have a height, of at least 0.5 mm. In an embodiment similar to the infusion tube system 100, a first protrusion forming a dosed curve may surround one or more vent openings while the connector needle or a fluid path opening is positioned on the outside of the dosed curve formed by the first protrusion.

The support structure 48 and the connector body 8 may form an integrated unit, i.e. molded in a single process as illustrated in the figures.

It should be noted that in addition to the exemplary embodiments of the invention shown in the accompanying drawings, the invention may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the invention to those skilled in the art.

LIST OF REFERENCES

1, 100, 102 infusion tube system

2 infusion tube

4 connector

6 proximal end of connector

8 connector body

10 distal end of connector body

12 proximal end of connector body

14 cavity

16 end wall

18 inner surface of end wall

20 outer surface of end wall

22 first vent opening

24 second vent opening

26 third vent opening

28 fourth vent opening

30 sidewall

32 inner surface of side wall

34 outer surface of side wall

36 membrane

38 first welding seam

40 second welding seam

42 connector needle

44 distal end of connector needle

46 sealing membrane area

48 support structure

50 sealing element

52 first protrusion

54 second protrusion

200 detail view

300 weld horn

301 body

302 first annular protrusion

304 second annular protrusion

X center axis X 

What is claimed is:
 1. A method of making a connector for an infusion tube system, the method comprising: forming a first vent opening that extends through an end wall of a connector body of the connector; forming a first protrusion that extends away from an inner surface of the end wall toward a distal end of the connector body, wherein forming the first protrusion comprises defining, only by the first protrusion, a curve that completely surrounds the first vent opening; establishing a fluid path to permit fluid communication between an infusion tube of the infusion tube system and a cavity at least partially surrounded by the connector body, wherein establishing the fluid path comprises arranging the fluid path outside of the curve and defining the fluid path by a needle that lies on a center axis of the connector; covering the first vent opening at the inner surface by a membrane such that the membrane extends outside of the curve to the needle; and welding the membrane to the inner surface along a first welding seam at the first protrusion.
 2. The method of claim 1, wherein the first vent opening is the only vent opening formed in the connector body.
 3. The method of claim 1, wherein forming the first protrusion comprises defining, only by the first protrusion, the curve such that the curve extends only partway around the center axis.
 4. The method of claim 1, wherein the inner surface has an annular portion that encircles the fluid path and defines a radially-outermost periphery of the inner surface relative to the center axis of the connector, and wherein forming the first protrusion comprises locating the first protrusion radially inward of the annular portion relative to the center axis such that the first protrusion does not define the radially-outermost periphery of the inner surface.
 5. The method of claim 4, wherein the annular portion of the inner surface is flat along the radially-outermost periphery of the inner surface all the way around the center axis of the connector.
 6. The method of claim 5, wherein the first vent opening is the only vent opening formed in the connector body.
 7. The method of claim 1, wherein welding the membrane to the inner surface comprises sealing the first vent opening at the first welding seam.
 8. The method of claim 7, wherein welding the membrane to the inner surface comprises forming a closed curve at the first welding seam surrounding at least the first vent opening.
 9. The method of claim 1, further comprising forming a support structure that extends in a proximal direction from the end wall and is sized to accommodate at least a part of an infusion tube of the infusion tube system.
 10. A method of making a connector for an infusion tube system, the method comprising: forming a first vent opening through an end wall of the connector; forming a first protrusion that extends away from an inner surface of the end wall, wherein forming the first protrusion comprises defining, only by the first protrusion, a curve that completely surrounds the first vent opening; defining a fluid path between an infusion tube of the infusion tube system and a cavity at least partially surrounded by the connector using a needle that lies on a center axis of the connector and is arranged outside of the curve; covering the first vent opening at the inner surface by a membrane; and welding the membrane to the inner surface along a first welding seam at the first protrusion.
 11. The method of claim 10, wherein the first vent opening is the only vent opening formed in the connector.
 12. The method of claim 10, wherein forming the first protrusion comprises defining, only by the first protrusion, the curve such that the curve extends only partway around the center axis.
 13. The method of claim 12, wherein the curve extends all the way around a curve axis that is spaced from the center axis in a radial direction.
 14. The method of claim 13, wherein the curve defines an oval shape.
 15. The method of claim 10, wherein welding the membrane to the inner surface comprises sealing the first vent opening at the first welding seam.
 16. The method of claim 15, wherein welding the membrane to the inner surface comprises forming a closed curve at the first welding seam surrounding at least the first vent opening.
 17. The method of claim 10, wherein welding the membrane to the inner surface comprises welding the membrane to the inner surface along the first welding seam at the first protrusion such that the membrane extends outside of the curve to the needle.
 18. The method of claim 10, wherein the inner surface has an annular portion that encircles the fluid path and defines a radially-outermost periphery of the inner surface relative to the center axis of the connector, and wherein forming the first protrusion comprises locating the first protrusion radially inward of the annular portion relative to the center axis such that the first protrusion does not define the radially-outermost periphery of the inner surface.
 19. The method of claim 18, wherein the annular portion of the inner surface is flat along the radially-outermost periphery of the inner surface all the way around the center axis of the connector.
 20. The method of claim 19, wherein the first vent opening is the only vent opening formed in the connector. 